Mapping tow splices in composite structures
First Claim
Patent Images
1. An apparatus configured to detect and identify tow segment end joint alignments through a thickness of a composite structure, the apparatus comprising:
- an automatic fiber placement machine comprising a compaction roller configured to compact a towa sensing device configured to detect, immediately after the compaction roller compacts the tow on a tool, a splice marking, such that the splice marking is at least one of;
on a surface of the tow, and within the tow;
a geometric database of the composite structure; and
a computer comprising a program code configured to;
receive data from the geometric database, determine a location of the splice marking within the composite structure, receive an inspection parameter, and generate a pass/fail status for the tow segment end joint alignments based upon the inspection parameter.
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Abstract
The three dimensional (3-D) locations of splices in pre-preg tows placed by an automatic fiber placement machine to form a laminated composite structure are mapped to allow visualization of alignment patterns in the splices.
61 Citations
20 Claims
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1. An apparatus configured to detect and identify tow segment end joint alignments through a thickness of a composite structure, the apparatus comprising:
- an automatic fiber placement machine comprising a compaction roller configured to compact a tow
a sensing device configured to detect, immediately after the compaction roller compacts the tow on a tool, a splice marking, such that the splice marking is at least one of;
on a surface of the tow, and within the tow;a geometric database of the composite structure; and a computer comprising a program code configured to;
receive data from the geometric database, determine a location of the splice marking within the composite structure, receive an inspection parameter, and generate a pass/fail status for the tow segment end joint alignments based upon the inspection parameter. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
- an automatic fiber placement machine comprising a compaction roller configured to compact a tow
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11. An apparatus configured to map and evaluate a three-dimensional alignment of tow segment end joints in pre-preg tows and to form a laminated composite structure, comprising:
- an automatic fiber placement machine comprising a compaction roller configured to compact a tow
at least one sensor configured to sense a splice marking after placing the tow onto a tool; a computer coupled with the sensor, the computer comprising program code configured to calculate a three-dimensional coordinate within the structure of each splice marking sensed by the sensor, receive an inspection parameter, and determine if the three-dimensional alignment of a first tow segment end joint relative to a second tow segment end joint meets the inspection parameter; and a display coupled with the computer configured to display an image showing the three-dimensional alignment of each splice marking through a thickness of the laminated composite structure. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
- an automatic fiber placement machine comprising a compaction roller configured to compact a tow
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19. An apparatus configured to manufacture a laminated composite aircraft structure, comprising:
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an automatic fiber placement machine, including a tape application head configured to place bands of pre-preg tows on a tool surface; at least one camera on the application head and configured to image areas of the band immediately after the pre-preg tows have been placed on the tool surface by a placement head, and the at least one camera further configured to record a three-dimensional location of a feature that is inside the pre-preg tows representing a splice in the tow; a laser configured to illuminate the area of the band imaged by the camera; a computer coupled with the camera, the computer configured comprising a program code configured to;
recognize the feature recorded by the camera, generate a three-dimensional data file representing a three-dimensional image of the structure, the three dimensional data file comprising the location of the splice, and a three-dimensional alignment of each splice through a thickness of the laminated composite aircraft structure, and further configured to receive inspection parameters and determine if the three-dimensional alignment of each splice through the thickness of the composite structure meets inspection parameters; anda display coupled with the computer, the display configured to display the three-dimensional image of the structure including the three-dimensional location of the splice through the thickness of the composite structure. - View Dependent Claims (20)
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Specification